Function and use of air compressor in chemical plant

In chemical plants, air compressors (air compressors) are one of the core power equipment, and their functions and uses run through multiple production links. The following is a detailed analysis based on industry applications and technical characteristics:

1. Core role

1. compressed gas power supply
   Air compressors compress air into high-pressure gas, providing a stable gas source for chemical production. For example:
   • Driving pneumatic equipment: Pneumatic valves, stirrers, conveyor belts, etc. rely on compressed air to operate.
   • combustion reaction support: Provide high-pressure pure oxygen for reactions that require oxygen (such as oxidation reactions) to improve reaction efficiency.
2. Gas synthesis and polymerization
   Under high pressure conditions, air compressors promote intermolecular reactions of gases:
   • synthetic ammonia: Nitrogen and hydrogen are synthesized into ammonia (NH) under high pressure and used in fertilizer production.
   • methanol synthesis: Carbon dioxide and hydrogen generate methanol (CH OH) under the action of a catalyst.
   • polyethylene production: Ethylene gas polymerizes under high pressure to form polyethylene plastic.
3. Refrigeration and gas separation
   • artificial refrigeration: After being cooled and liquefied, compressed air is used in refrigeration systems (such as Freon compressors).
   • gas separation: After compressing the mixed gas, use the difference in boiling points to separate components (such as petroleum cracked gas separation).

2. Specific uses

1. Production process support
   • transport fluid: Use compressed air to transport powder and particulate materials (such as catalysts, plastic particles).
   • equipment cleaning: High-pressure air purges the inner wall of the pipeline and reaction vessel to remove residues.
2. safety and environmental protection
   • explosion protection: In flammable and explosive environments, use compressed air instead of electric drive to reduce the risk of sparks.
   • exhaust gas treatment: Provide oxidizing air for environmentally friendly equipment (such as desulfurization towers) to improve treatment efficiency.
3. automation control
   • instrument power: Drive pneumatic regulating valves and shut-off valves to achieve precise process control.
   • signal transmission: Used as a signal transmission medium in the control system (such as pneumatic logic components).

3. Special application scenarios

1. high-temperature, high-pressure process
   In petrochemicals, air compressors provide high-pressure hydrogen or steam for hydrogenation reactions and catalytic cracking.

2. waste heat recovery
   Some air compressors are equipped with waste heat recovery systems, which use the heat generated by the compression process to preheat raw materials or heat, increasing the energy-saving efficiency by 15%-20%.

3. Corrosion resistant design
   For the corrosiveness of chemical media, the air compressor is made of stainless steel or special coating to extend its service life.

4. Selection and maintenance suggestions

1. equipment selection
   • power matching: Select the displacement according to the air consumption (such as 50-300 m³/min) to avoid “big horses and small cars”.
   • pressure rating: 0.7-1.0 MPa is selected for conventional processes, and customized models are required for high-pressure reactions (such as above 30 MPa).
2. maintenance points
   • regular maintenance: Check the quality of the cooling system and lubricating oil to prevent overheating or insufficient lubrication.
   • spare parts stores: Establish inventory of vulnerable parts (such as filter elements and piston rings) to reduce downtime.

V. Summary

In chemical plants, air compressors are not only simple gas supply equipment, but also the key to process optimization and safe production. From gas synthesis to automated control, its application deeply affects production capacity and efficiency. It is recommended that companies choose screw or centrifugal air compressors according to process characteristics, and combine them with intelligent monitoring systems to optimize energy consumption to further enhance competitiveness.